Tub for a washing machine appliance with fluid overflow control

ABSTRACT

A wash tub for a washing machine appliance is provided. The wash tub includes one or more features for controlling an overflow condition in which fluid is flowing over the side of the wash tub. These features can be used to help control the flow of fluid and/or direct the same away from the machine.

FIELD OF THE INVENTION

The subject matter of the present disclosure relates to a tub for a washing machine that includes features for fluid overflow control.

BACKGROUND OF THE INVENTION

Conventionally, a vertical axis washing machine appliance includes a tub or drum that holds both fluid and the articles that are to be washed during the cleaning process. After the user makes selections regarding e.g., wash and rinse cycles, the washing machine operates one or more valves to fill the tub with a certain amount of water based on the anticipated size of the article load. The valves are connected with a pressurized water supply. Additives such as detergent and fabric softeners may also be added manually or automatically. The tub may be drained and filled several times depending upon the wash and rinse cycles selected or programmed for the cleaning process.

By way of example, in order to control the amount of fluid added into the tub, the washing machine may be equipped with a fluid level sensor. Preferably, once the fluid in the tub reaches a certain height as detected by the sensor, one or more valves are closed so as not to cause the fluid to flow over the side of the tub. Other methods for regulating the fluid level may be used as well.

Unfortunately, one or more components of the washing can malfunction such that too much fluid is fed into the wash tub. For example, the valve(s) controlling the flow of water into the tub may fail in an open position, the level sensor may malfunction, and/or other conditions can lead to an over supply of fluid. As a result, the fluid can eventually flow over the side of the tub—i.e. create an overflow condition. This uncontained fluid may cause external damage to the floor or other surroundings where the washing machine is located. Additionally, the uncontained fluid can damage internal, particularly electrical, components of the washing machine.

Generally speaking, there can be two modes in an overflow condition. The first mode occurs when the fluid has completely filled the tub and just begins to start overflowing and free falling down the wall of the tub. The second mode is after the fluid has started flowing out of the tub and reaches a steady state condition between the amount of fluid flowing in and out of the wash tub. In this second mode, the full flow of water allowed by the valve(s) into the washing machine must exit out of the wash tub. In this second mode of flow, the risk of damage to internal components of the washing machine is increased because as this continuous flow of wash fluid gains kinetic energy falling down the side of the tub, the amount of splashing and spreading of the fluid is increased.

Accordingly, a washing machine having one or more features for controlling an overflow condition would be useful. More particularly, a washing machine having a tub that can help minimize or slow the free fall of fluid from the tub at e.g., the onset of overflow would be helpful. Such a tub that can direct fluid from the overflow away from the machine, particularly energized components thereof, would also be beneficial.

BRIEF DESCRIPTION OF THE INVENTION

Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

In one exemplary embodiment, the present invention provides a washing machine that includes a wash tub for the containment of fluids used during washing and rinsing. The wash tub includes a wall having an exterior surface that defines a plurality of substantially vertical ribs, a top edge defining a notch positioned near a top of the plurality of substantially vertical ribs, and a dam positioned adjacent to the notch and having a height greater than the notch. The dam and the wall define a channel at the top of the ribs. The channel is configured for directing the overflow of water from the wash tub between the dam and the exterior surface of the wall. A wash basket is rotatably mounted in the wash tub. The wash basket has a wash basket opening for receiving wash fluid and a wash load therein. A motor is in mechanical communication with the wash basket and is configured for causing the wash basket to rotate.

In another exemplary embodiment, the present invention provides, a wash tub for a washing machine appliance. The wash tub includes a substantially cylindrical container for the receipt of articles and fluid for washing. The container has an exterior surface extending between a top and a bottom of the container. The top of the container has an opening. The wash tub includes a plurality of fluid guides positioned along the exterior surface of the container and extending substantially vertical between the top and bottom of the container. A pass is defined within a top edge of the container. The pass is configured for allowing fluid to overflow from the container before rising to the top edge. The pass is positioned over the guides. A wall portion is positioned proximate to the pass near the top of the container. The wall portion and the exterior surface of the container form a channel therebetween for fluid overflowing from the container. A ramp is positioned near the bottom of the container and below at least a portion of the fluid guides. The ramp extends outwardly from the container so as to divert an overflow of fluid away from the container.

These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 provides a perspective view of an exemplary embodiment of a washing machine of the present invention.

FIG. 2 provides a partial, cross-sectional view of the exemplary embodiment of FIG. 1;

A side view of an exemplary embodiment of a wash tub of the present invention is illustrated in FIG. 3;

FIG. 4 is a perspective, partial cross-sectional view of the wash tub of FIG. 3;

FIG. 5 is a close-up and partial cross-sectional view at the top of the wash tub shown in FIGS. 3 and 4;

FIG. 6 is a partial, top down view of the overflow area of the wash tub shown in FIGS. 3-5.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a wash tub for a washing machine appliance. More particularly, the wash tub includes one or more features for controlling an overflow condition in which fluid is flowing over the side of the wash tub. These features can be used to help control the flow of fluid and/or direct the same away from the machine.

Reference now will be made in detail to embodiments of the invention, one or more examples of which are illustrated in the drawings. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope or spirit of the invention. For instance, features illustrated or described as part of one embodiment can be used with another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

FIG. 1 is a perspective view of an exemplary vertical axis washing machine 50 including a cabinet 52 and a cover 54. FIG. 2 provides a partial, cross-sectional view of washing machine 50. A backsplash 56 extends from cover 54, and a control panel 58 including a plurality of input selectors 60 is coupled to backsplash 56. Control panel 58 and input selectors 60 collectively form a user interface input for operator selection of machine cycles and features, and in one embodiment, a display 48 indicates selected features, a countdown timer, and/or other items of interest to machine users. A lid 62 is mounted to cover 54 and is rotatable about a hinge (not shown) between an open position (not shown) facilitating access to wash tub 64 (shown in FIG. 2) located within cabinet 52 and a closed position (shown in FIG. 1) forming an enclosure over wash tub 64.

FIG. 2 provides a partial cross-sectional view of the exemplary washing machine 50 of FIG. 1. As shown, wash tub 64 includes a bottom wall 66 and a sidewall 68. A basket 70 is rotatably mounted within wash tub 64. A pump assembly (not shown) is located beneath tub 64 and basket 70 for gravity assisted flow when draining tub 64. Basket 70 includes a plurality of perforations 71 therein to facilitate fluid communication between an interior of basket 70 and wash tub 64.

An agitation element 92, such as a vane agitator, impeller, auger, or oscillatory basket mechanism, or some combination thereof, is disposed in basket 70 to impart an oscillatory motion to articles and liquid in basket 70. In different embodiments, agitation element 92 includes a single action element (i.e., oscillatory only), double action (oscillatory movement at one end, single direction rotation at the other end) or triple action (oscillatory movement plus single direction rotation at one end, singe direction rotation at the other end). As illustrated in FIG. 2, agitation element 92 is oriented to rotate about a vertical axis A. Basket 70 and agitator 92 are driven by pancake motor 94. As motor output shaft 98 is rotated, basket 70 and agitation element 92 are operated for rotatable movement within wash tub 64. Washing machine 50 may also include a brake assembly (not shown) selectively applied or released for respectively maintaining basket 70 in a stationary position within tub 64 or for allowing basket 70 to spin within tub 64.

Operation of machine 50 is controlled by a controller or processing device (not shown), that is operatively coupled to the user interface input located on washing machine backsplash 56 (shown in FIG. 1) for user manipulation to select washing machine cycles and features. In response to user manipulation of the user interface input, the controller operates the various components of machine 50 to execute selected machine cycles and features.

In an illustrative embodiment, laundry items are loaded into basket 70, and washing operation is initiated through operator manipulation of control input selectors 60. Wash tub 64 is filled with water and mixed with detergent to form a wash fluid. One or more valves (not shown) can be controlled by washing machine 50 to provide for filling tub 64 to the appropriate level for the amount of articles being washed. Once tub 64 is properly filled with fluid, the contents of the basket 70 are agitated with agitation element 92 for cleansing of laundry items in basket 70. More specifically, agitation element 92 is moved back and forth in an oscillatory motion.

After the agitation phase of the wash cycle is completed, tub 64 is drained. Laundry articles can then be rinsed by again adding fluid to wash tub 64, depending on the particulars of the cleaning cycle selected by a user, agitation element 92 may again provide agitation within basket 70. One or more spin cycles may also be used. In particular, a spin cycle may be applied after the wash cycle and/or after the rinse cycle in order to wring wash fluid from the articles being washed. During a spin cycle, basket 70 is rotated at relatively high speeds.

As previously described, during any of the wash, rinse, or spin cycles, one or more valves are opened to provide a fluid (e.g., water along with detergent or rinse additives) into wash tub 64. Preferably such valves are properly controlled so that only a certain amount of fluid is introduced into wash tub 64. However, in the event of a malfunction of one or more components of washing machine 50, fluid may be allowed to flow continuously into wash tub 64. As such, unless the malfunction is discovered, fluid can eventually fill tub 64 and begin to run over tub 64 and down sidewall 68. This can lead to damage such as e.g., contamination of motor 94.

Accordingly, FIG. 3 provides a side view of an exemplary embodiment of a wash tub 100 of the present invention. FIG. 4 provides cross-sectional view of a portion of wash tub 100. As shown, wash tub 100 is configured as a substantially cylindrical container that can be constructed e.g., from various plastic materials. Wash tub 100 provides for maintaining fluids and the laundry articles during the cleaning process.

Wash tub 100 includes a wall 114 that provides an exterior surface 106 extending between the top 108 and the bottom 110 of tub 100. The top 108 of wash tub 103 includes an opening 112 through which laundry articles and fluid may be placed into tub 100, it being understood that the laundry articles are also captured within a wash basket such as basket 70 shown in FIG. 2.

Wash tub 100 is provided with an overflow area 102 having features that help to control the flow of fluid from tub 100 in the event of an overflow condition. More specifically, for this exemplary embodiment, the exterior surface 106 of wall 114 includes a plurality of fluid guides or ribs 104. Although other configurations may be used, for this exemplary embodiment ribs 104 are shown as substantially vertical and extend between the top 108 and bottom 110 of tub 100. During an overflow condition, ribs 104 help guide the flow of fluid D down the exterior surface 106 of wall 114.

As shown in FIGS. 4 and 5, wall 114 has a top edge 116 that defines a pass or notch 118 over which fluid may travel during an overflow condition. Notch 118 is a portion of wall 114 at overflow area 102 that is lower than top edge 116. As a fluid fills tub 100, the fluid will eventually reach notch 118 before top edge 116 and begin to flow over notch 118 during an overflow condition.

Overflow area 102 also includes a wall portion or dam 120 that is positioned adjacent to notch 118. Dam 120 has an upper edge 122 that is positioned above notch 122 but below the top edge 116 of drum 100. As shown in FIGS. 4-6, dam 120 and wall 114 define a channel 124 for the flow through of fluid from wash tub 100. The distance separating dam 120 and wall 114 determines the cross-sectional area of channel 124 through with the fluid may flow. By way of example, in one preferred embodiment, the distance separating dam 120 and wall 114 is less than about 0.400 inches, or is about 0.323 inches. In still another embodiment, the distance separating dam 120 and wall 114 is in the range of about 0.025 inches to about 0.4 inches, or is in the range of about 0.025 inches to about 0.323 inches. Other configurations may be used well. The length of channel 124 is determined by the amount of overlap between dam 120 and wall 144 along the vertical direction.

Additionally, as shown in FIG. 4, overflow area 102 also includes a ramp 126 positioned below ribs 104. As shown, ramp 126 provides an angled surface that is sloped away from dam 120. Fluid reaching ramp 126 is, therefore, directed away from tub 100 by ramp 126.

For this exemplary embodiment, ribs 104 extend into channel 124. As best shown in FIG. 3, ribs 104 are substantially parallel as they extend between the top 108 and bottom 110 of wash tub 100. Near bottom 110, ribs 104 diverge from one another. Using the teachings disclosed herein, one of ordinary skill in the art will understand that a variety of other configurations may be used for ribs 104 including different shapes and placement on wash tub 100.

Referring again to FIG. 4, as fluid level L rises in tub 100, it eventually reaches notch 118 and begins an overflow condition. As shown by arrows F, fluid in tub 10 then flows toward and over notch 118 and into channel 124. Channel 124 helps to control the kinetic energy of the fluid and while also deterring the fluid from splashing out of tub 100. As the fluid flows though channel 124, it travels down wall 144 as shown by arrow D, it is guided by ribs 104. Upon reaching ramp 126, the fluid is directed away from the bottom 110 of tub 104.

Accordingly, wash tub 100 can provide a laundry washing appliance with features that help control the flow of fluid during an overflow condition. Channel 124, rib 104, and/or ramp 126 help prevent or lessen splashing and spattering and help protect internal components of the appliance—particularly energized components.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 

What is claimed is:
 1. A washing machine, comprising: a wash tub for the containment of fluids used during washing and rinsing, said wash tub comprising: a wall having an exterior surface that defines a plurality of substantially vertical ribs; a top edge defining a notch positioned near a top of the plurality of substantially vertical ribs; a dam positioned adjacent to the notch and having a height greater than the notch, the dam and the wall defining a channel at the top of the ribs, the channel configured for directing the overflow of water from said wash tub between the dam and the exterior surface of the wall; a wash basket rotatably mounted in said wash tub, said wash basket having a wash basket opening for receiving wash fluid and a wash load therein; and a motor in mechanical communication with said wash basket and configured for causing said wash basket to rotate.
 2. A washing machine as in claim 1, further comprising: an outwardly sloped ramp defined by the wall of said wash tub near a bottom of the ribs, the ramp configured for diverting a flow of water away from said wash tub.
 3. A washing machine as in claim 1, wherein the ribs extend into the channel.
 4. A washing machine as in claim 1, wherein the channel has a thickness in the range of about 0.025 inches to about 0.323 inches.
 5. A washing machine as in claim 1, wherein the dam has an upper edge that is lower than the top edge of said wash tub.
 6. A washing machine as in claim 1, wherein said wash tub comprises a plastic material.
 7. A washing machine as in claim 1, wherein the ribs diverge near a bottom of the wall of said wash tub.
 8. A washing machine as in claim 1, wherein the ribs are substantially parallel near a top of the ribs and diverge near a bottom of the ribs.
 9. A washing machine as in claim 1, wherein the ribs and the dam are contained within an overflow area located along one side of said wash tub.
 10. A wash tub for a washing machine appliance, the wash tub including a substantially cylindrical container for the receipt of articles and fluid for washing, the container having an exterior surface extending between a top and a bottom of the container, the top of the container having an opening, the wash tub comprising: a plurality of fluid guides positioned along the exterior surface of the container and extending substantially vertical between the top and bottom of the container; a pass defined within a top edge of the container, the pass configured for allowing fluid to overflow from the container before rising to the top edge, the pass positioned over the guides; a wall portion positioned proximate to the pass near the top of the container, the wall portion and the exterior surface of the container forming a channel therebetween for fluid overflowing from the container; and a ramp positioned near the bottom of the container and below at least a portion of the fluid guides, the ramp extending outwardly from the container so as to divert an overflow of fluid away from the container.
 11. A wash tub for a washing machine appliance as in claim 10, wherein the fluid guides extend into the channel.
 12. A wash tub for a washing machine appliance as in claim 10, wherein the fluid guides diverge near the bottom of the container.
 13. A wash tub for a washing machine appliance as in claim 10, wherein the fluid guides extend along the ramp.
 14. A wash tub for a washing machine appliance as in claim 10, wherein the channel has a thickness in the range of about 0.025 inches to about 0.323 inches.
 15. A wash tub for a washing machine appliance as in claim 10, wherein the pass has an upper edge that is lower than the top edge of the container.
 16. A wash tub for a washing machine appliance as in claim 10, wherein the flow guides are substantially parallel near a top of the flow guides and diverge near a bottom of the flow guides.
 17. A wash tub for a washing machine appliance as in claim 10, wherein the ribs and the dam are contained within an overflow area located along one side of said wash tub. 